An automatic temperature measuring and controlling system for a battery aluminum foil smelting furnace

Abstract

This invention proposes an automatic temperature measurement and control system for a battery aluminum foil melting furnace, comprising: a communicating vessel-type liquid storage chamber for containing molten aluminum; a distributed thermocouple array, including a high-zone thermocouple array, a middle-zone thermocouple array, and a low-zone thermocouple array, respectively disposed in the high, middle, and low zones of the liquid storage chamber, each array containing at least four measuring points; a temperature controller connected to the thermocouple array; a gas proportional valve connected to the temperature controller; and a burner connected to the gas proportional valve. The temperature controller includes: a temperature signal acquisition module; a temperature gradient tensor generation module; a coupling suppression control algorithm module for calculating a gas flow correction vector based on the temperature gradient tensor; and a fuzzy adaptive execution module for adjusting the opening of the gas proportional valve based on the gas flow correction vector. This achieves precise and stable control of the molten aluminum temperature, meeting the high standards required for battery aluminum foil production.

Description

Technical Field

[0001] This invention relates to an automatic temperature measurement and control system for a battery aluminum foil melting furnace. Background Technology

[0002] This invention relates to the field of aluminum melt temperature control technology, and in particular to a multi-zone dynamic temperature control system and method for aluminum melt used in the production of battery aluminum foil blanks.

[0003] In the production process of battery aluminum foil blanks, temperature control of the molten aluminum is a critical factor affecting the quality of the final product. Currently, traditional battery aluminum foil melting furnaces typically monitor the molten aluminum temperature using single-point temperature measurement or intermittent manual temperature measurement, and control the temperature by manually adjusting the burner flame. This technical approach has significant limitations: First, single-point temperature measurement cannot fully reflect the temperature distribution of the molten aluminum in the furnace. Because there is a temperature gradient between the upper and lower layers of the molten aluminum in the furnace, local temperature deviations are prone to exceed the process requirements, resulting in unstable quality of the finished aluminum foil. Second, temperature control mainly relies on the operator's experience and lacks the ability to make real-time dynamic adjustments, resulting in large fluctuations in the temperature of the molten aluminum (usually exceeding ±5℃), which makes it difficult to meet the high precision requirements of battery aluminum foil for the purity and temperature stability of the molten aluminum. In addition, this method wastes fuel gas.

[0004] Furthermore, existing temperature control methods lack precise algorithmic support and cannot dynamically optimize natural gas supply based on temperature data from multiple regions, further limiting the accuracy and response speed of temperature control.

[0005] Therefore, this invention proposes a multi-region temperature dynamic control system and method for molten aluminum to solve the above problems. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide an automatic temperature measurement and control system for battery aluminum foil melting furnaces, aiming to achieve precise and stable control of the aluminum melt temperature and meet the high standards required for battery aluminum foil production. This objective is achieved as follows: In one aspect, this invention proposes an automatic temperature measurement and control system for a battery aluminum foil melting furnace, comprising: a communicating vessel-type liquid storage chamber for containing molten aluminum; a distributed thermocouple array, including a high-zone thermocouple array, a middle-zone thermocouple array, and a low-zone thermocouple array, respectively disposed in the high, middle, and low zones of the liquid storage chamber, each array containing at least 4 measuring points; a temperature controller connected to the thermocouple array; a gas proportional valve connected to the temperature controller; and a burner connected to the gas proportional valve. The temperature controller includes: a temperature signal acquisition module for acquiring the original signal from the thermocouple array; a temperature gradient tensor generation module for generating a temperature gradient tensor based on the original signal; a coupling suppression control algorithm module for calculating a gas flow correction vector based on the temperature gradient tensor; and a fuzzy adaptive execution module for adjusting the opening of the gas proportional valve based on the gas flow correction vector.

[0007] Furthermore, the step of generating a temperature gradient tensor based on the original signal includes: obtaining the calibration temperature value of the j-th measuring point in the i-th region according to a first preset formula, the original signal value of the j-th measuring point in the i-th region, the thermocouple dynamic response compensation coefficient, the vertical heat conduction correction factor, and the depth of the j-th measuring point from the liquid surface. The first preset formula is as follows: ,in, This represents the calibration temperature value at the j-th measuring point in the i-th region. This represents the original signal value at the j-th measurement point in the i-th region; This is the thermocouple dynamic response compensation coefficient; This is a correction factor for heat conduction in the vertical direction; Let be the depth of the j-th measuring point from the liquid surface.

[0008] Furthermore, the step of calculating the gas flow correction vector based on the temperature gradient tensor includes: obtaining the gas flow correction amounts for the high, middle, and low zones according to a second preset formula, the average temperature deviation of the high, middle, and low zones, the inter-regional thermal interference suppression gain, and the total height of the melt surface. The second preset formula is as follows: ,in, , , These are the gas flow correction amounts for the high, medium, and low zones, respectively. , , These represent the average temperature deviations for the high, middle, and low zones, respectively. , , Gain for suppressing inter-regional thermal interference; This is the total height of the melt surface; To dynamically adjust the scaling factor; is the integral coefficient.

[0009] Furthermore, the fuzzy adaptive execution module bases its calculations on the absolute value of the temperature deviation in each formula. The dynamic adjustment ratio coefficient in each formula is adjusted based on the comparison results with the preset threshold. The This represents the absolute value of the average temperature deviation in the high, middle, and low zones.

[0010] Furthermore, the fuzzy adaptive execution module bases its calculations on the absolute value of the temperature deviation in each formula. The dynamic adjustment ratio coefficient in each formula is adjusted based on the comparison results with the preset threshold. Including: when At that time, the fuzzy adaptive execution module adjusts the parameters according to the following steps: when the temperature deviation is Large and the rate of change is Fast, Increase by 25%; when the temperature deviation is Medium and the rate of change is Slow, Increase by 12%; when the temperature deviation is Small and the rate of change is Negative, Reduced by 8%.

[0011] On the other hand, this invention proposes a multi-zone dynamic temperature control method for aluminum melt, used to implement an automatic temperature measurement and control system for a battery aluminum foil melting furnace, comprising the following steps: Step S1: Deploying thermocouple arrays in the high, middle, and low zones of a communicating vessel-type liquid storage chamber, each array containing at least 4 measuring points; Step S2: Setting the target value of the temperature controller and initializing the opening of the gas proportional valve; Step S3: Acquiring the raw signals of the thermocouple arrays and generating a temperature gradient tensor; Step S4: Calculating a gas flow correction vector based on the temperature gradient tensor; Step S5: Adjusting the opening of the gas proportional valve based on the gas flow correction vector.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: by arranging a high-density, multi-region thermocouple array, three-dimensional real-time monitoring of the temperature field of molten aluminum is realized, overcoming the limitations of single-point temperature measurement, and the temperature monitoring coverage is improved by more than 300%; the multivariable decoupling control algorithm based on the temperature gradient tensor effectively suppresses inter-region thermal interference, enabling the temperature control accuracy of molten aluminum to reach within ±1℃; the fuzzy adaptive execution module enables the system to adjust the control parameters in advance according to the temperature change trend, shortening the response time to within 0.5 seconds, which significantly improves speed and accuracy compared with manual operation; By dynamically and collaboratively adjusting the gas flow rate, the overall temperature standard deviation of the aluminum melt is reduced to below 0.6℃, avoiding energy waste and reducing natural gas consumption by 15-20%, resulting in significant economic and environmental benefits.

[0013] 1. High level of technological innovation and system integration This invention combines distributed sensing technology, temperature field reconstruction algorithms, multivariable decoupled control, and fuzzy adaptive execution to construct a complete intelligent temperature control system for molten aluminum. This system not only achieves a leap from single-point monitoring to three-dimensional temperature field perception, but also realizes the digital characterization of the thermal process through temperature gradient tensor analysis. It provides a theoretical basis and engineering implementation path for high-precision temperature control, and is a typical example of the intelligent and refined upgrading of traditional smelting processes.

[0014] 2. Temperature control accuracy and stability are significantly improved. By arranging a high-density, multi-region thermocouple array, the system achieves comprehensive, real-time, three-dimensional monitoring of the temperature field of molten aluminum, increasing the monitoring coverage by more than 300% and completely overcoming the blind spots and errors of traditional single-point temperature measurement.

[0015] The coupling suppression control algorithm based on temperature gradient tensor effectively identifies and compensates for thermal interference between regions, and realizes coordinated optimization and control of the high, medium and low temperatures. This enables the overall temperature control accuracy of the aluminum melt to reach within ±1℃, and the temperature standard deviation to be reduced to below 0.6℃, fully meeting the extremely high process requirements of battery aluminum foil for melt temperature uniformity and stability.

[0016] 3. Strong dynamic response speed and adaptive capability The fuzzy adaptive execution module can dynamically adjust control parameters (such as proportional coefficient KpKp) according to the magnitude and trend of temperature deviation, realizing feedforward-feedback composite control. The system response time is shortened to less than 0.5 seconds, which greatly improves the timeliness and predictability of regulation.

[0017] The system has good robustness and adaptability, and can cope with external disturbances such as gas pressure fluctuations and changes in aluminum material addition during the production process, maintaining continuous and stable temperature control.

[0018] 4. Energy efficiency has been significantly improved, and the effects of energy conservation and emission reduction are outstanding. By dynamically and collaboratively adjusting the gas flow, the system achieves "on-demand heating," avoiding excessive gas supply or insufficient heating caused by temperature fluctuations. Actual operation data has verified that it can reduce natural gas consumption by 15-20%, demonstrating significant economic and environmental benefits.

[0019] Efficient combustion and precise temperature control also reduce the generation of harmful gases such as nitrogen oxides, which aligns with the development direction of green manufacturing and clean production.

[0020] 5. Production process optimization and product quality improvement A stable aluminum melt temperature directly improves the internal structure uniformity, surface quality, and mechanical properties of aluminum foil blanks, providing a high-quality raw material guarantee for subsequent rolling processes and reducing the defect rate of finished products caused by temperature fluctuations.

[0021] The system supports traceability and adaptive optimization of process parameters, providing data support for process improvement and quality control, and helping to achieve standardized and digital management of the production process.

[0022] 6. High level of automation and intelligence, reducing reliance on manual labor. The system operates fully automatically, reducing reliance on operator experience, lowering the risk of human error, and improving production safety and consistency.

[0023] It has remote monitoring, fault diagnosis and early warning functions, and supports integration with factory MES / SCADA systems, providing key technical equipment for realizing "lights-out factories" and intelligent manufacturing.

[0024] 7. System scalability and industry promotion value The multi-zone temperature dynamic control method and system architecture proposed in this invention are not only applicable to battery aluminum foil melting furnaces, but can also be extended to other high-precision temperature control scenarios such as non-ferrous metal melting, glass furnaces, and heat treatment furnaces, and have broad industry applicability and technology transfer value. Attached Figure Description

[0025] Figure 1 This is a flowchart illustrating an automatic temperature measurement and control system for a battery aluminum foil melting furnace. Detailed Implementation

[0026] To enhance understanding of the present invention, the present invention will be further described in detail below with reference to embodiments and accompanying drawings. These embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0027] In one aspect, this invention proposes an automatic temperature measurement and control system for a battery aluminum foil melting furnace, comprising: a communicating vessel-type liquid storage chamber for containing molten aluminum; a distributed thermocouple array, including a high-zone thermocouple array, a middle-zone thermocouple array, and a low-zone thermocouple array, respectively disposed in the high, middle, and low zones of the liquid storage chamber, each array containing at least 4 measuring points; a temperature controller connected to the thermocouple array; a gas proportional valve connected to the temperature controller; and a burner connected to the gas proportional valve; wherein the temperature controller comprises: a temperature signal acquisition module for acquiring the original signal from the thermocouple array; a temperature gradient tensor generation module for generating a temperature gradient tensor based on the original signal; a coupling suppression control algorithm module for calculating a gas flow correction vector based on the temperature gradient tensor; and a fuzzy adaptive execution module for adjusting the opening of the gas proportional valve based on the gas flow correction vector.

[0028] Demonstratively, this system can be applied to the aluminum smelting furnace in a battery aluminum foil blank production line to achieve precise control of the aluminum melt temperature. The communicating vessel-type liquid storage chamber is a cuboid structure made of high-temperature resistant alloy steel, with an internal volume of 5m³ to hold the aluminum melt. The side wall of the liquid storage chamber has three layers of mounting holes for fixing high-zone, middle-zone, and low-zone thermocouple arrays, respectively. The bottom of the liquid storage chamber has a discharge port, and the top has a feed port and a waste gas discharge port. The interior of the liquid storage chamber also has guide plates to promote convection of the aluminum melt and reduce temperature stratification. The guide plates are at a 30° angle to the horizontal plane and spaced 200mm apart, effectively enhancing heat exchange between the upper and lower layers of the melt. The high-zone thermocouple array, middle-zone thermocouple array... Both the thermocouple array and the low-zone thermocouple array 4 use K-type thermocouples with a temperature measurement range of 0-1000℃ and an accuracy of ±0.5℃. Each array contains 8 measuring points, which are evenly distributed along the length of the liquid storage chamber 1, with an adjacent measuring point spacing of 150mm. The high-zone thermocouple array is located 100mm from the liquid surface, the middle-zone thermocouple array is located 300mm from the liquid surface, and the low-zone thermocouple array is located 500mm from the liquid surface. This arrangement can comprehensively monitor the temperature distribution of the aluminum melt at different heights and horizontal positions. The temperature controller is electrically connected to the thermocouple array and is used to realize the dynamic control of the aluminum melt temperature. The temperature controller adopts an industrial-grade PLC with computer program instructions embedded inside.

[0029] Further, generating a temperature gradient tensor based on the original signal includes: obtaining the calibration temperature value of the j-th measuring point in the i-th region based on the original signal value at the j-th measuring point in the i-th region, the thermocouple dynamic response compensation coefficient, the vertical heat conduction correction factor, and the depth of the j-th measuring point from the liquid surface, according to a first preset formula. The first preset formula is as follows: ,in, This represents the calibration temperature value at the j-th measuring point in the i-th region. This represents the original signal value at the j-th measurement point in the i-th region; This is the thermocouple dynamic response compensation coefficient; This is a correction factor for heat conduction in the vertical direction; Let be the depth of the j-th measuring point from the liquid surface.

[0030] Specifically, the temperature controller acquires the raw signals from the thermocouple array at a frequency of 10Hz through a temperature signal acquisition module. ,in Indicates the area , , , This indicates that the measurement points are numbered 1-8. The acquired signals are converted using a 16-bit analog-to-digital converter and then stored in matrix form. .

[0031] Further, the calculation of the gas flow correction vector based on the temperature gradient tensor includes: obtaining the gas flow correction amounts for the high, middle, and low zones according to a second preset formula, the average temperature deviation of the high, middle, and low zones, the inter-regional thermal interference suppression gain, and the total height of the melt surface. The second preset formula is as follows: ,in, , , These are the gas flow correction amounts for the high, medium, and low zones, respectively. , , These represent the average temperature deviations for the high, middle, and low zones, respectively. , , Gain for suppressing inter-regional thermal interference; This is the total height of the melt surface; To dynamically adjust the scaling factor; is the integral coefficient.

[0032] As an example, the temperature gradient tensor generation module processes the original signal to generate a calibrated temperature gradient tensor. The specific algorithm is as follows: ,in, This is the thermocouple dynamic response compensation coefficient, used to eliminate the measurement delay caused by the thermal inertia of the thermocouple; This is a vertical heat conduction correction factor used to compensate for the vertical heat conduction effect of molten aluminum. For the first The depth of the measuring point from the liquid surface; for example, for the third measuring point in the high zone, if the original signal is measured... Depth from the liquid surface Calculated The calibration temperature is: The coupling suppression control algorithm module is based on the temperature gradient tensor. Calculate the gas flow correction vector The specific algorithm is as follows: , in, For the region The average temperature deviation; , , These represent the thermal interference suppression gains between the three regions; The total height of the melt surface is given by the measured average temperature of the high-temperature zone. Average temperature in the central region Target temperature The correction amount for the high-zone gas flow rate is: Furthermore, the fuzzy adaptive execution module calculates the absolute value of the temperature deviation in each formula. The dynamic adjustment ratio coefficient in each formula is adjusted based on the comparison results with the preset threshold. , This represents the absolute value of the average temperature deviation in the high, middle, and low zones.

[0033] Furthermore, the fuzzy adaptive execution module calculates the absolute value of the temperature deviation in each formula. The dynamic adjustment ratio coefficient in each formula is adjusted based on the comparison results with the preset threshold. Including: when At that time, the fuzzy adaptive execution module adjusts the parameters according to the following steps: when the temperature deviation is Large and the rate of change is Fast, Increase by 25%; when the temperature deviation is Medium and the rate of change is Slow, Increase by 12%; when the temperature deviation is Small and the rate of change is Negative, Reduced by 8%.

[0034] As an example, the gas proportional valve is an electric regulating valve with a flow rate adjustment range of 0-100 m³ / h and an adjustment accuracy of ±0.5%. The gas proportional valve receives a PWM signal sent by the temperature controller and adjusts its opening according to the signal duty cycle to control the gas flow. The burner is a high-speed temperature-adjustable burner, which is connected to the gas proportional valve through a gas pipeline. The burner generates a flame of corresponding size according to the gas flow to heat the molten aluminum. The flame temperature of the burner can be finely adjusted by the gas / air ratio, with an adjustment range of 700-1000℃.

[0035] Please refer to Figure 1 On the other hand, this invention proposes a multi-zone dynamic temperature control method for aluminum melt, used to implement an automatic temperature measurement and control system for a battery aluminum foil melting furnace, comprising the following steps: Step S1: Deploy thermocouple arrays in the high, middle, and low zones of the communicating vessel-type liquid storage chamber, with each array containing at least 4 measuring points; Step S2: Set the target value of the temperature controller and initialize the opening of the gas proportional valve; Step S3: Acquire the original signal of the thermocouple array and generate a temperature gradient tensor; Step S4: Calculate the gas flow correction vector based on the temperature gradient tensor; Step S5: Adjust the opening of the gas proportional valve based on the gas flow correction vector.

[0036] In one possible implementation scenario, after the system is powered on, the temperature controller performs a self-test, initializes various parameters, and sets the target temperature. Initial gas proportional valve opening , , Thermocouple arrays in the high, medium, and low zones acquire the temperature of the molten aluminum at a frequency of 10Hz. The temperature signal acquisition module then converts the raw signal... The original signal is converted into a digital signal and stored. The temperature gradient tensor generation module calibrates the original signal and generates a temperature gradient tensor. The coupling suppression control algorithm module is based on Calculate the gas flow correction vector; the fuzzy adaptive execution module dynamically adjusts based on the temperature deviation. and The temperature controller converts the gas flow correction into a PWM signal and sends it to the gas proportional valve. The gas proportional valve adjusts its opening according to the signal, changing the gas flow. The burner generates a flame of corresponding size according to the gas flow, heating the molten aluminum and gradually bringing its temperature closer to the target temperature. The system executes steps 2-5 in a 100ms cycle to achieve dynamic control of the aluminum melt temperature.

[0037] In summary, the multi-region dynamic temperature control system for molten aluminum provided in this embodiment of the invention, by setting up a distributed thermocouple array and employing a coupling suppression control algorithm, can achieve precise temperature control of molten aluminum. Specific effects are as follows: High temperature monitoring accuracy: temperature gradient tensor reconstruction error ≤ ±0.5℃, 4 times higher than single-point temperature measurement accuracy; multi-region control response time ≤ 0.5 seconds, 3 times faster than manual operation; overall temperature standard deviation of molten aluminum ≤ 0.6℃, meeting the requirements. The process requirements are met; natural gas consumption is reduced by 15-20%.

[0038] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. An automatic temperature measurement and control system for a battery aluminum foil melting furnace, characterized in that, include: A communicating vessel-type liquid storage chamber for containing molten aluminum; a distributed thermocouple array, including a high-zone thermocouple array, a middle-zone thermocouple array and a low-zone thermocouple array, respectively arranged in the high, middle and low zones of the liquid storage chamber, each array containing at least 4 measuring points; A temperature controller is connected to the thermocouple array; A gas proportional valve is connected to the temperature controller; The burner is connected to the gas proportional valve; The temperature controller includes: a temperature signal acquisition module for acquiring the original signal from the thermocouple array; a temperature gradient tensor generation module for generating a temperature gradient tensor based on the original signal; a coupling suppression control algorithm module for calculating a gas flow correction vector based on the temperature gradient tensor; and a fuzzy adaptive execution module for adjusting the opening of the gas proportional valve based on the gas flow correction vector.

2. The automatic temperature measurement and control system for a battery aluminum foil melting furnace according to claim 1, characterized in that, The step of generating a temperature gradient tensor based on the original signal includes: obtaining the calibration temperature value of the j-th measuring point in the i-th region based on a first preset formula, the original signal value of the j-th measuring point in the i-th region, the thermocouple dynamic response compensation coefficient, the vertical heat conduction correction factor, and the depth of the j-th measuring point from the liquid surface. The first preset formula is... ,in, This represents the calibration temperature value at the j-th measuring point in the i-th region. This represents the original signal value at the j-th measurement point in the i-th region; This is the thermocouple dynamic response compensation coefficient; This is a correction factor for heat conduction in the vertical direction; Let be the depth of the j-th measuring point from the liquid surface.

3. The automatic temperature measurement and control system for a battery aluminum foil melting furnace according to claim 2, characterized in that, The step of calculating the gas flow correction vector based on the temperature gradient tensor includes: obtaining the gas flow correction amounts for the high, middle, and low regions according to a second preset formula, the average temperature deviation of the high, middle, and low regions, the inter-regional thermal interference suppression gain, and the total height of the melt surface. The second preset formula is... ,in, , , These are the gas flow correction amounts for the high, medium, and low zones, respectively. , , These represent the average temperature deviations for the high, middle, and low zones, respectively. , , Gain for suppressing inter-regional thermal interference; This is the total height of the melt surface; To dynamically adjust the scaling factor; is the integral coefficient.

4. The automatic temperature measurement and control system for a battery aluminum foil melting furnace according to claim 3, characterized in that, The fuzzy adaptive execution module calculates the absolute value of the temperature deviation in each formula. The dynamic adjustment ratio coefficient in each formula is adjusted based on the comparison results with the preset threshold. The This represents the absolute value of the average temperature deviation in the high, middle, and low zones.

5. The automatic temperature measurement and control system for a battery aluminum foil melting furnace according to claim 4, characterized in that, The fuzzy adaptive execution module calculates the absolute value of the temperature deviation in each formula. The dynamic adjustment ratio coefficient in each formula is adjusted based on the comparison results with the preset threshold. Including: when At that time, the fuzzy adaptive execution module adjusts the parameters according to the following steps: when the temperature deviation is Large and the rate of change is Fast, Increase by 25%; when the temperature deviation is Medium and the rate of change is Slow, Increase by 12%; when the temperature deviation is Small and the rate of change is Negative, Reduced by 8%.

6. A method for dynamic temperature control of multi-zone aluminum melt, used to execute the automatic temperature measurement and control system for a battery aluminum foil melting furnace as described in claims 1-5, characterized in that, The process includes the following steps: Step S1: Deploy thermocouple arrays in the high, middle, and low zones of the communicating vessel-type liquid storage chamber, with each array containing at least 4 measuring points; Step S2: Set the target value for the temperature controller and initialize the opening of the gas proportional valve; Step S3: Acquire the raw signals from the thermocouple arrays and generate a temperature gradient tensor; Step S4: Calculate the gas flow correction vector based on the temperature gradient tensor; Step S5: Adjust the opening of the gas proportional valve based on the gas flow correction vector.

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